Cable Fairlead - Redirect of cable to clear flap pushrod

[DesertBearhawk]

Guys,

I am working to install the fairlead that moves the aileron cable to clear the flap push rod. I am not liking the idea of the cable rubbing on the fairlead. Is this the best way to do this or has someone done this differently? Those of you that have flying Bearhawks, what kind of wear are you seeing in tis area. My experience tells me that the cable is going to wear and not the nylon fairlead.

Would a small pulley be better in this area?

Please Advise.

[jaredyates]

The cable tension is really quite low, at around 30 pounds.

[Enewton57]

Generally speaking, you only need a pulley when the cable changes direction significanlty. The little deflection you are talikng about won't really cause much wear.

[Dan R.]

I used pulleys instead of fairleads. No fairlead should be used if it redirects the cable more that 3 degrees. http://www.risingup.com/fars/info/part29-685-FAR.shtml Look at #7. Dan

[Battson]

I would add that getting the pulley aligned correctly is equally important - that cable eats up the phenolic pulley material pretty fast otherwise.

[Dan R.]

The pulleys in the picture are aligned correctly. Dan

[Battson]

Dan, I wasn't trying to suggest your pulleys are not aligned, I was just adding a thought to the thread, based upon my experience on misalignment. Jonathan

[DesertBearhawk]

Dan, you have pictures of what you did in the wing?

[Dan R.]

Just installed the pulleys instead of the guides for the flap cable. Dan

[DesertBearhawk]

Understood, would Ike to see how you did that. How did you mount the pulley, what design.

[marcusofcotton]

I measured the cable angle change at the aileron cable fairlead at the rear spar near the flap drive. Came out at .5 (half) degree on mine.

Mark J

[DesertBearhawk]

Yeah, I installed per the manuals, not as big a deal as I thought and certainly not worth reinventing the wheel!